SWITCH POINT R55 Color Mark Sensor Color Registration Mark Sensor with Solid-State White Light Source R55 Features Outstanding color contrast sensitivity; detects 16 gray scale changes Reliably detects the toughest color mark contrasts, including 20% llow against ite Totally solid-state: no lbs to replace and no need to switch between different colored light sources Rugged zinc alloy die-cast housing with high-quality acrylic lens suitable for food processing applications; rated IP67, NEMA 6 Fixed-convergent sensing at 10 ±3 mm (0.39 ±0.12 inch); rectangular sensing image measures 1.2 mm x 3.8 mm (0.05" x 0.15") at 10 mm from the lens 50 microsecond sensing response (10,000 operations per second) 10 to 30V dc operation; all models offer both NPN and PNP digital outputs, plus 0 to 10 ma analog output Switch-selectable light or dark operate; selectable output timing functions: 50 ms off-delay; 50 ms non-retriggerable one-shot, and 100 ms retriggerable one-shot 15-turn sensitivity control permits accurate setup; 10-element light bar signal strength display makes setup easy and fast Choose models with either horizontal or vertical sensing image (see chart below) 2 meter (6.5') integral cable or 5-pin euro-style 300 mm (12") pigtail quick disconnect; 9 meter (30') integral cable is also available R55CG1 0 to 10mA 10-30 V dc R55 Convergent Mode Visible ite, 450-650 nm Models Focus Cable Supply Voltage Type Sensing Image Orientation R55CW1 2 m (6.5')* Parallel to sensor length R55CW1Q R55CW1QP R55CW2 10 mm (0.39") Integral 5-pin Euro-Style QD** 5-pin Euro-Style pigtail QD** 2 m (6.5')* 10-30V dc Bipolar NPN/PNP Analog 0-10 ma Perpendicular to sensor length R55CW2Q Integral 5-pin Euro-Style QD** R55CW2QP 5-pin Euro-Style pigtail QD** For R55 Sensors: * 9 m (30') cables are available by adding suffix W/30 to the model number of any cabled sensor (e.g., R55CW1 W/30) ** A model with a QD connector requires an accessory mating cable. See the Accessories section on page 8 for more information. Printed in USA P/N 59341
R55 Color Mark Sensor White LED Product Description The R55 offers maintenance-free solid-state reliability, with the sensing performance until now offered only by short-lived incandescent color mark sensors. The R55 reliably detects all color contrasts found in common product registration color mark applications even such extremely low contrasts as 20 percent llow printed on ite. In addition, a ite LED light source and hybrid optics eliminate the need to switch between different color light sources for different color contrasts. Champa Champa Champa Champa C hampa Champagne 50 microsecond sensing response produces excellent registration repeatability, even in ultra-high-speed applications. This fast response, coupled with the small 0.05" x 0.15" sensing image, allows color marks to be made small and inconspicuous. The R55 has ilt-in pulse-stretching output timing logic to permit reliable interfacing to slower inputs, such as those associated with some programmable logic controllers (PLCs). A 4-position DIP switch is accessed beneath the tethered switch cap (see figure 2). Switch #1 selects light operate (outputs energize en the lighter of the two colors is sensed) or dark operate (outputs energize en the darker of the two colors is sensed). Switch #2 selects a 50 millisecond non-retriggerable one-shot pulse. Switch #3 selects a 50 millisecond off delay. When switches #2 and #3 are both turned to OFF, the output is a 100 millisecond retriggerable one-shot. The R55 offers a 10-element moving LED light bar ich displays signal strength, relative to the switch point setting. The display is invaluable during setup (see Sensitivity Adjustment on page 5). Switch #4 is used to disable the light bar display during normal operation, if desired. R55CG1 0 to 10mA 15-turn Sensitivity Adjustment Tethered Switch Cap 10-30 V dc 10-element Moving LED Light Bar SENSITIVITY MODE 2 DELAY ṄO 20ms 3 DELAY ṄO 30ms 4 DISPLAY ȮN OFF Indicator The sensor has two bipolar outputs: one sinking (NPN) and one sourcing (PNP). Both switching outputs will switch loads up to 150 ma. A third dedicated 0 to 10 ma analog output may be used for applications such as measuring or monitoring surface brightness or texture. See Specifications and Hookup (pages 6-7) for more information. The construction of the R55 is extremely rost with a die-cast metal housing, plastic optics, and IP67 and NEMA 6 leakproof design for harsh sensing environments. Figure 1. R55 Features page 2
R55 Color Mark Sensor White LED R55 Mode Settings The four switches located behind the tethered cap labeled MODE are used to select the functions shown in the table below. R55CG1 1 2 3 4 Switches On Off 2. ONE-SHOT NO 50ms 3. OFF-DELAY NO 50ms 4. DISPLAY ON OFF 0 to 10mA 10-30 V dc SENSITIVITY MODE 2 ONE SHOT ṄO 50ms 3 OFF DELAY ṄO 50ms 4 DISPLAY ȮN OFF Tethered Switch Cap Figure 2. R55 Mode Settings R55 DIP Switch Setting Configurations Switch Function Description 1 Dark Operate (D.O.) Light Operate (L.O.) Switching outputs energize at transition from light to dark Switching outputs energize at transition from dark to light 50 ms 50 ms 2 no one-shot timer 50 millisecond non-retriggerable one-shot Sensor Sensing Event 50 ms 50 ms 3 no OFF delay timer 50 millisecond OFF delay timer Sensor Sensing Event 100 ms 100 ms 2 & 3 no output timer 100 millisecond retriggerable one-shot Sensor Sensing Event 4 10-element light bar display is enabled 10-element light bar display is disabled NOTE: Factory setting is all switches in ON position. page 3
R55 Color Mark Sensor White LED Lens Location The lens of the R55 may be installed at either of two lens ports (see Figure 3). The lens and the lens port cap are both threaded and may be exchanged by hand; no tools are required. The lens and cap both include an o-ring seal. Mounting Surface of Material Figure 3. Lens R55 Lens Positions The R55 includes a total of eight size M5 threaded holes used for mounting (see dimension drawing on page 8). These threaded holes are positioned to match the mounting hole patterns found on competitive color mark sensors. The R55 includes four M5 x 0.8 x 6 mm stainless steel cap screws and a hex key wrench. The R55 focus is located at 10 mm (0.39") ahead of the lens surface. The R55 must be mounted within 3 mm (0.12") of this distance from the surface of the material for reliable sensing (Figure 3). Cap 10 ± 3 mm Cap 10 ± 3 mm Lens Consider the following en mounting the R55: 1) When sensing a color mark on a reflective (shiny) material, mount the R55 at an angle ich places the lens centerline at approximately 15º off perpendicular to the material s surface (see Figure 4b). This skew angle will minimize strong direct reflections (ich tend to overelm the sensor), and allow the sensor to discern the relatively small optical contrast offered by difference in colors. 2) Clear materials are poor reflectors of light. When sensing a mark printed on a clear material (e.g., a clear poly web), position a reflective surface directly behind the clear material ich will return light to the R55. The printed mark, regardless of its color, then becomes the dark condition, as it blocks the light from reaching the reflective surface. Most clear materials are also shiny; it is important also to include a 15º skew angle en sensing clear materials (Figure 4b). 3) Whenever possible, it is a good idea to sense a web material at a location ere it passes over a tension bar or roller, to minimize the adverse affects of web flutter or sag (Figure 4a). Roller or Tension Bar 90º R55 Mount the R55 Perpendicular to non-reflective (matte) materials Approximately 15º Focus Distance 10.0 mm (0.39 in) Opaque, Non-reflective Web Material Figure 4a. Mounting for sensing opaque non-reflective materials R55 Transparent or Opaque Reflective Web Material Focus Distance 10.0 mm (0.39 in) Roller or Tension Bar Mount the R55 at approximately 15º from perpendicular to transparent and opaque reflective materials Figure 4b. Mounting for sensing opaque reflective and transparent materials page 4
R55 Color Mark Sensor White LED Sensitivity Adjustment Light Condition Dark Condition LED Segment #1 LED Segment #10 Figure 5a. High Contrast (Best) Light Condition Dark Condition Figure 5b. Minimum Recommended Contrast Light Condition Dark Condition The 10-element moving LED light bar displays received light signal strength, relative to the switch point setting. This display makes sensitivity adjustment extremely easy and accurate. Every color registration mark application involves sensing the difference between two colors, ich relates, optically, to differentiating between two gray scale levels (one color returns more reflected light to the sensor than the other). The condition ich returns the greater amount of light is referred to as the light condition. The light condition is usually obvious to the e. However, the light bar displays exactly how the sensor sees the difference between the color mark and its background. The Switch Point is electronically maintained between segments 5 and 6 of the 10-element moving LED light bar display (Figure 5a). The digital outputs switch enever there is a transition across the Switch Point (in either direction). After mounting the R55 (see page 4), apply power to the sensor. Hookup information is shown on a side label of the R55, and on page 7. Alternately present the light and the dark conditions to the R55, and adjust its Sensitivity so that the Switch Point is centered between the light bar readings for the two sensing conditions (Figure 5). NOTE: The Sensitivity adjustment is a 15-turn potentiometer ich is clutched at both ends to prevent damage. It free-eels at both the top and the bottom end of its adjustment range. (Clockwise rotation increases sensitivity.) Figure 5c. Low Contrast All Sensing Variables Must Remain Stable Figure 5. Sensitivity Adjustment; Light and Dark Condition Settings Should be Equally Spaced from the Switch Point Sensing Contrast In any photoelectric application, the difference in received light level between the light and dark conditions is called the optical contrast. In general, the greater the contrast, the more reliable the sensing application will be and the more forgiving the sensor will be to sensing variables such as vibration of the material being sensed. Contrast is indicated on the light bar by the distance between the light condition and the dark condition; they should be equally spaced on either side of the Switch Point. The best possible contrast is displad en the light condition displays at segment 10 (far right) and the dark condition displays at segment 1 (far left). The minimum recommended sensing contrast for most applications will display two segments above and below the Switch Point. Sensing for a contrast ich registers at segments 5 and 6 should be reserved for applications ich are perfectly stable (ere no sensing variables such as vibration, color variations, surface variations, etc. are allowed). See Figure 5. page 5
R55 Color Mark Sensor White LED R55 Color Mark Sensor (White LED) Specifications Supply Voltage and Current Supply Protection Circuitry Configuration 10 to 30V dc (including 10% maximum ripple) at less than 70 ma (exclusive of load) Protected against reverse polarity and transient voltages Digital outputs are bipolar: one current sourcing (PNP) and one current sinking (NPN) open-collector transistor Analog output is a current source ich is proportional to the received light level Rating Digital outputs are 150 ma maximum (each) Off-state leakage current <10 microamps at 30V dc Saturation voltage (NPN output) <2.0V at 150 ma dc Saturation voltage (PNP output) <1.5V at 150 ma dc Analog output: 0 to 10 ma Maximum load voltage drop is V supply minus 7 volts (3V at V supply = 10V; 23V at V supply = 30V) Protection Circuitry Response Time Sensing Image Adjustments Indicators Construction Environmental Rating Connections Operating Temperature Vibration and Mechanical Shock Application Notes All outputs are protected against false pulse on power-up and continuous overload or short circuit of outputs <50 microseconds ON and OFF with no output delay timing selected (NOTE: 100 millisecond delay on power-up; NPN & PNP outputs are non-conducting at this time) Rectangular: 1.2 mm x 3.8 mm (0.05" x 0.15") at 10 mm (0.39") from face of lens; image oriented either parallel or perpendicular to sensor length, depending on model (see page 1) 15-turn Sensitivity control with external knob Four DIP switches select the following functions: Switch #1: Light or dark operate Switch #2: 50 millisecond non-retriggerable one-shot Switch #3: 50 millisecond off delay Switches #2 and #3: 100 millisecond retriggerable one-shot Switch #4: Enable/disable for 10-element light bar 10-element green moving LED light bar displays signal strength, relative to the switch point setting Green LED output indicator Zinc alloy die-cast housing with steel cover, both with black acrylic polyurethane finish Lens, lens port cap, Sensitivity control, and Mode switch cap are o-ring sealed Lens and light bar display window are acrylic Lens port cap and lens holder are ABS Mode switch cap is Delrin Sensitivity control knob is Nylon NEMA 6, IP67 PVC-jacketed 5-conductor 2 m (6.5') or 9 m (30') attached cable, or 5-pin Euro-style quick disconnect on 300 mm (12") cable pigtail. Mating QD cables are purchased separately. See Accessories section, page 7. Temperature: -10 to 55 C (14 to 131 F) Maximum relative humidity: 90% at 50 C (non-condensing) All models meet IEC 68-2-6 and IEC 68-2-27 testing criteria. Mount sensor at approximately a 15 angle en sensing color marks on shiny, reflective materials (do not mount sensor exactly perpendicular to shiny material surfaces). Minimize web or product flutter enever possible for greatest sensing reliability. Certifications page 6 Delrin is a registred trademark of Dupont Co.
POINT R55 Color Mark Sensor White LED R55 Hookup Diagrams R55 Sensor with Attached Cable R55 Sensor with Quick Disconnect 0 to 10 ma 10-30V dc gy 0 to 10 ma 10-30V dc R55 Color Mark Sensor Dimensions 18.0 mm (0.71") Models with integral 5-pin Euro Quick disconnect fitting (model suffix Q) Indicator 10-element Display M12 x 1 Thread 7.0 mm (0.28") 28.0 mm 39.0 mm (1.54") M5 x 0.8 Thread x 6.3 mm Deep (8 Holes) SENSITIVITY 55.5 mm (2.19") 25 mm (1.0") 2. ONE SHOT NO 50ms MODE 3. OFF DELAY NO 50ms 4. DISPLAY ON OFF 15 mm (0.59") 5.0 mm (0.20") 92 mm (3.6") 28.0 mm 80.0 mm (3.15") 43.0 mm (1.69") 3 mm (0.12") 15.0 mm (0.59") 3.0 mm (0.12") R55CG1 0 to 10mA 10-30 V dc SWITCH SENSITIVITY 2 DELAY ṄO 20ms 3 DELAY ṄO 30ms 4 DISPLAY ȮN OFF 30.4 mm (1.20") 21.0 mm (0.83") 30.0 mm (1.18") Models with 300 mm (12") pigtail terminated with 5-pin Euro quick disconnect fitting (model suffix QP) MODE 15.0 mm (0.59") M12 x 1 Thread Quick-Disconnect (QD) Cables Style Model Length Connector 5-Pin Euro MQDC1-506 MQDC1-515 MQDC1-530 MQDC1-506RA MQDC1-515RA MQDC1-530RA 2 m (6.5') 5 m (15') 9 m (30') 2 m (6.5') 5 m (15') 9 m (30') Straight Straight Straight Right-angle Right-angle Right-angle Brown Wire Black Wire White Wire Blue Wire Gray Wire page 7
R55 Color Mark Sensor White LED SMB55F 12-ga. 300 series stainless steel Flat-mount bracket Mounting Brackets SMB55A 12-ga. 300 series stainless steel 15 offset bracket 82.6 mm (3.25") 2.6 mm 15.2 mm (0.60") 11.4 mm (0.45") 24.1 mm (0.95") 4 x R6.4 mm (0.25") 13.3 mm (0.53") 12.7 mm (0.50") 8 x R3.3 mm (0.13") 31.8 mm (1.25") 2.6 mm 15.2 mm (0.60") 11.4 mm (0.45") 24.1 mm (0.95") 13.3 mm (0.53") 12.7 mm (0.50") 8 x R3.3 mm (0.13") 24.8 mm (0.98") 2 x 12.4 mm (0.49") 2 x 5.6 mm (0.22") 2 x 7.6 mm (0.30") 25.4mm (1.00") C L 27.9 mm 5.4 mm (0.21") 12 X R2.6 mm 24.8 mm (0.98") 2 x 12.4 mm (0.49") 2 x 5.6 mm (0.22") 2 x 7.6 mm (0.30") 25.4mm (1.00") C L 27.9 mm 15.0 5.4 mm (0.21") 12 x R2.6 mm 4 x R6.4 mm (0.25") SMB55RA 12-ga. 300 series stainless steel Right-angle bracket SMB55S 12-ga. 300 series stainless steel 15 offset bracket 5.4 mm (0.21") 12 X R2.6 mm 31.8 mm (1.25") 2 x 12.4 mm (0.49") 2.6 mm 24.8 mm (0.98") 25.4mm (1.00") 15.2 mm (0.60") C L 27.9 mm 2 x 7.6 mm (0.30") 2 x 5.6 mm (0.22") 11.4 mm (0.45") 24.1 mm (0.95") 13.3 mm (0.53") 12.7 mm (0.50") 4 x R6.4 mm (0.25") 7.9 mm (0.31") 3.8 mm (0.15") 8.2 mm (0.32") 44.5 mm (1.75") 28.0 mm 2.6 mm 25.4 mm (1.00") 4x R2.6 2x 10.2 mm (0.40") 8.1 mm (0.32") 10.2 mm (0.40") 34.3 mm (1.35") 15.0 30.5 mm (1.20") 7.1 mm (0.28") 4x R6.4 mm (0.25") 8x R3.3 mm (0.13") 8 x R3.3 mm (0.13") WARRANTY: Banner Engineering Corp. warrants its products to be free from defects for one ar. Banner Engineering Corp. will repair or replace, free of charge, any product of its manufacture found to be defective at the time it is returned to the factory during the warranty period. This warranty does not cover damage or liability for the improper application of Banner products. This warranty is in lieu of any other warranty either expressed or implied.! WARNING... Not To Be Used for Personnel Protection Never use these products as sensing devices for personnel protection. Doing so could lead to serious injury or death. These sensors do NOT include the self-checking redundant circuitry necessary to allow their use in personnel safety applications. A sensor failure or malfunction can cause either an energized or de-energized sensor output condition. Consult your current Banner Safety Products catalog for safety products ich meet OSHA, ANSI and IEC standards for personnel protection. Banner Engineering Corp., 9714 Tenth Ave. No., Minneapolis, MN 55441 Phone: 612.544.3164 Fax: 612.544.3213 E-mail: sensors@baneng.com